JP7255556B2 - Manufacturing method of stator for rotary electric machine for vehicle - Google Patents

Description

The present invention relates to a method of manufacturing a stator that constitutes a rotating electric machine for a vehicle.

2. Description of the Related Art A stator that constitutes a rotating electrical machine for a vehicle includes a ring-shaped stator core and conductors housed in slots that are spaces formed in the inner peripheral portion of the stator core. Insulating paper is interposed between the stator core and the conductor. The stator described in Patent Literature 1 is one of them. In Patent Document 1, in order to suppress the positional deviation of the insulating paper in the slot, a pair of engaging grooves are provided on the wall surfaces facing each other forming the slot and have locking grooves capable of locking both ends of the insulating paper. It is described to have a stop groove formation.

JP 2019-135892 A

By the way, the pair of locking groove forming portions of Patent Document 1 are provided on the inner peripheral side of the slot in the radial direction of the stator core, and the length of the conducting wire arranged in the slot is increased by the amount of the locking groove forming portions provided. There was a problem that the number of books decreased.

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and its object is to provide a stator that constitutes a rotating electric machine for a vehicle, in which a stator core and a lead wire accommodated in a slot formed in the stator core are connected. To provide a method for manufacturing a stator having a structure capable of suppressing a decrease in the number of conductor wires accommodated in slots while preventing displacement of insulating paper interposed between them.

The gist of the first invention is (a) an annular stator core, a slot which is a groove formed in the inner peripheral portion of the stator core and penetrates the stator core, a wall surface of the slot, and a stator accommodated in the slot. an insulating paper interposed between a conductor and disposed so as to surround the conductor, wherein the insulating paper radially inside the stator core extends toward the inner peripheral side of the stator core. A method of manufacturing a stator for a rotating electric machine for a vehicle, which has a protruding portion formed thereon, comprising: (b) inserting the insulating paper into the slot of the stator core; A jig is arranged on the side opposite to the side where the conductor wire is inserted and overlaps with the protrusion when viewed in the direction in which the conductor wire is inserted into the slot of the stator core, and the conductor wire is inserted into the slot. and a step of performing.

The gist of the second invention is that in the stator manufacturing method of the first invention, one end and the other end of the insulating paper surrounding the conductor are arranged at positions different from radially inner positions of the stator core. It is characterized by

The gist of the third invention is that in the stator manufacturing method of the first invention or the second invention, a space surrounded by the projection and the conductor is formed between the projection and the conductor. It is characterized by

According to the stator manufacturing method of the first aspect of the invention, the first step of inserting the insulating paper into the slots of the stator core is performed, and the stator core is placed on the side opposite to the side where the conductors are inserted into the slots of the stator core. Since the jig is arranged at a position overlapping the protrusion when viewed in the direction of insertion and the step of inserting the conductor wire into the slot is performed, the insulating paper may be dragged by the conductor wire in the process of inserting the conductor wire into the slot. Even if there is, the insulating paper abuts against the jig, thereby suppressing the movement of the insulating paper and preventing the insulating paper from being displaced from the slot. Moreover, since it is not necessary to provide a locking groove forming portion in the slot to prevent the insulating paper from slipping on the opening side of the slot, it is possible to prevent the number of conductor wires to be accommodated in the slot from being reduced.

According to the stator manufacturing method of the second aspect of the invention, the one end and the other end of the insulating paper surrounding the conductor are arranged at positions different from the positions radially inside the stator core. of rigidity is ensured. Therefore, it is possible to prevent the protrusion from being deformed by the jig when the protrusion contacts the jig in the process of inserting the conductor wire into the slot.

According to the stator manufacturing method of the third aspect of the invention, since the space is formed between the projection and the conductor wire, the coolant flows through the space formed between the projection and the conductor wire. improves cooling.

1 is a cross-sectional view showing a part of a vehicle drive system provided in a vehicle to which the present invention is applied; FIG. FIG. 2 is a cross-sectional view of the stator of FIG. 1 cut along a cutting line X; 3 is an enlarged cross-sectional view of one of the slots of FIG. 2; FIG. FIG. 2 is a diagram illustrating a method of winding a stator coil around a stator core of the rotating electric machine for a vehicle in FIG. 1; FIG. 10 is a view of the stator core viewed from the side opposite to the side where the segment coils are inserted into the slots in the axial direction in the process of inserting the arm portions of the segment coils into the slots of the stator core; FIG. 2 is a flow chart explaining a manufacturing process of the stator of FIG. 1; FIG. FIG. 8 is an enlarged cross-sectional view showing the periphery of slots formed in the stator core, corresponding to another embodiment of the present invention; FIG. 11 is an enlarged cross-sectional view of the periphery of slots formed in the stator core, corresponding to still another embodiment of the present invention; FIG. 11 is an enlarged cross-sectional view of the periphery of slots formed in the stator core, corresponding to still another embodiment of the present invention; FIG. 11 is an enlarged cross-sectional view of the periphery of slots formed in the stator core, corresponding to still another embodiment of the present invention; FIG. 10 is a view of the stator core seen from the side opposite to the side where the segment coils are inserted in the process of inserting each arm of the segment coil into the slots of the stator core, corresponding to still another embodiment of the present invention; FIG. 11 is a view of the transitional state in which segment coils are inserted into the slots of the stator core, viewed from the inner side to the outer side in the radial direction of the stator core in FIG. 11 .

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In the following examples, the drawings are appropriately simplified or modified, and the dimensional ratios, shapes, etc. of each part are not necessarily drawn accurately.

FIG. 1 is a sectional view showing a part of a vehicle drive system 10 (hereinafter referred to as drive system 10) provided in a vehicle to which the present invention is applied. The driving device 10 is provided in, for example, an electric vehicle or a hybrid vehicle. The drive device 10 includes a vehicle rotating electric machine MG (hereinafter referred to as a rotating electric machine MG) that functions as a driving force source of the vehicle in a case 12 that is a non-rotating member.

A motor chamber 18 partitioned by a partition wall 16 is formed in the case 12, and the rotating electric machine MG is accommodated in the motor chamber 18. As shown in FIG. The rotary electric machine MG is arranged rotatably around the axis CL.

The rotary electric machine MG includes a stator 22 that is non-rotatably fixed to the case 12 and a rotor 20 that is arranged on the inner peripheral side of the stator 22 . The rotor 20 includes an annular rotor core 24 and a rotor shaft 26 integrally connected to the inner circumference of the rotor core 24 .

The stator 22 includes an annular stator core 27 and stator coils 28 attached to the stator core. The stator core 27 is configured by laminating a plurality of disc-shaped magnetic steel plates 23 . The stator core 27 is non-rotatably fixed to the case 12 by a plurality of bolts 30 .

The rotor core 24 is arranged on the inner peripheral side of the stator core 27 . The rotor core 24 is constructed by stacking a plurality of disc-shaped electromagnetic steel plates 25 . A pair of end plates 32 and 34 are arranged on both sides of the rotor core 24 in the direction of the axis CL, and the rotor core 24 is held between the end plates 32 and 34 . The rotor core 24 also incorporates a magnet 36 .

The rotor shaft 26 is formed in a cylindrical shape and is rotatably supported about the axis CL by bearings 38 and 40 arranged at both ends in the axial direction (that is, in the direction of the axis CL). A rotor core 24 is integrally fixed to the outer peripheral surface of the rotor shaft 26 .

FIG. 2 is a cross-sectional view of the stator 22 of FIG. 1 taken along the cutting line X. As shown in FIG. 2, only a portion of the stator 22 in the circumferential direction is shown. As shown in FIG. 2 , the stator 22 has a stator core 27 and stator coils 28 . Hereinafter, the inner circumference (inner side) and the outer circumference (outer side) of the stator core 27 correspond to the inner circumference (inner side) and the outer circumference (outer side) in the radial direction about the axis line CL.

The stator core 27 is formed in an annular shape by stacking a plurality of disc-shaped electromagnetic steel plates 23 . A plurality of slots 42 are formed in the inner peripheral portion of the stator core 27 . The slot 42 is a slot formed in the inner peripheral portion of the stator core 27 and extending radially outward from the inner peripheral surface of the stator core 27 . The slots 42 are radially formed at equal angular intervals in the circumferential direction of the stator core 27 . The slots 42 pass through the stator core 27 in the direction of the axis CL. In relation to this, a plurality of teeth 44 protruding toward the inner circumference are formed between the slots 42 adjacent in the circumferential direction. A stator coil 28 is wound around each tooth 44 . The stator coil 28 is a three-phase coil consisting of U-phase, V-phase and W-phase.

Each slot 42 accommodates a plurality of (six in this embodiment) segment coils 46 that form the stator coil 28 . A plurality of segment coils 46 accommodated in each slot 42 are arranged side by side in the radial direction of the stator core 27 within the slot 42 . As shown in FIG. 2, each segment coil 46 has a rectangular cross section. Each segment coil 46 is formed in a substantially U shape as described later. A pair of arm portions 46a and 46b (see FIG. 4) forming the segment coil 46 are inserted into different slots 42, respectively. When the stator 22 is manufactured, a pair of arm portions 46a and 46b forming the segment coil 46 are inserted parallel to the axis CL of the stator core 27 from one side to the other in the direction of the axis CL. That is, the direction in which the segment coils 46 are inserted into the slots 42 of the stator core 27 (hereinafter referred to as the insertion direction of the segment coils 46) is parallel to the direction of the axis CL. Incidentally, the segment coil 46 corresponds to the conducting wire of the present invention.

FIG. 3 is an enlarged cross-sectional view of one of the slots 42 of FIG. In FIG. 3 , the lower side of the paper corresponds to the inner peripheral side (diametrically inner side) of the stator core 27 , and the upper side of the paper corresponds to the outer peripheral side (radial outer side) of the stator core 27 .

The slots 42 are formed as slots extending radially outward from the inner peripheral surface of the stator core 27 . By forming the slots 42 , an opening 54 is formed through which the inner peripheral surface of the stator core 27 opens. The slot 42 is surrounded by a pair of side walls 48a and 48b formed substantially parallel to the radial direction of the stator core 27, and a bottom wall 50 located radially outside of the stator core 27 and connecting the side walls 48a and 48b. ing. The wall surfaces of the side wall 48a and the side wall 48b face each other and are formed parallel to each other. The bottom wall 50 is the outermost wall in the radial direction of the stator core 27 among the walls forming the slots 42 . The bottom wall 50 connects both ends of the pair of side walls 48a and 48b.

Each segment coil 46 is arranged in a row in the radial direction of the stator core 27 within the slot 42 . Each segment coil 46 is arranged such that the long side of the rectangular cross section extends along the circumferential direction of the stator core 27 and the short side extends along the radial direction of the stator core 27 .

Insulating paper 52 is interposed between the wall surfaces of the walls (side walls 48a, 48b, bottom wall 50) forming the slots 42 of the stator core 27 and the segment coils 46 accommodated in the slots 42. As shown in FIG. The insulating paper 52 is made of an insulating member such as aramid paper, nonwoven fabric, or resin material. As shown in FIG. 3, the insulating paper 52 is appropriately folded so that the insulating paper 52 wraps around the plurality of segment coils 46 accommodated in the slots 42 when viewed in the insertion direction of the segment coils 46. arranged to surround. Also, the insulating paper 52 has a dimension in the direction of the axis CL of the stator core 27 so as to cover the entire walls (side walls 48a, 48b, bottom wall 50) forming the slot 42 of the stator core 27. are assumed to be approximately the same.

As shown in FIG. 3, the insulating paper 52 includes a first portion 52a interposed between the side wall 48a of the slot 42 and the segment coil 46, and a first portion 52a interposed between the side wall 48b of the slot 42 and the segment coil 46. a third portion 52c inserted between the bottom wall 50 of the slot 42 and the segment coil 46; and a fourth portion 52d located radially inside the stator core 27. ing. The first portion 52 a and the second portion 52 b longitudinally extend along the radial direction of the stator core 27 .

One end 56a and the other end 56b of the insulating paper 52 are arranged in the third portion 52c and overlap each other. In this manner, the one end 56a and the other end 56b of the insulating paper 52 are positioned at a position different from the position of the fourth portion 52d of the insulating paper 52, that is, the radially inner position of the stator core 27 (the position of the opening 54 of the slot 42). It is arranged in a certain third portion 52c.

A fourth portion 52 d of the insulating paper 52 located inside the stator core 27 in the radial direction is formed with a projecting portion 58 projecting toward the inner peripheral side of the stator core 27 . The projecting portion 58 is formed in a convex shape projecting toward the inner peripheral side of the stator core 27 .

When viewed in the insertion direction of the segment coil 46, the projection 58 has a U-shaped cross section. The projecting portion 58 is formed of a pair of projecting portions 60a and 60b projecting toward the inner peripheral side of the stator core 27, and a connecting portion 62 connecting both ends of the pair of projecting portions 60a and 60b. The pair of protrusions 60 a and 60 b have the same size in the radial direction of the stator core 27 . Therefore, the connecting portion 62 is located radially inside the stator core 27 by the length of the projecting portions 60 a and 60 b from the segment coil 46 accommodated in the slot 42 . In this regard, a space 64 surrounded by the projections 60a, 60b of the projection 58, the connecting portion 62, and the long sides of the segment coil 46 is formed between the projection 58 and the segment coil 46. there is The oil flowing through the space 64 effectively cools the stator core 27 and the stator coil 28 by the oil flowing through the space 64 .

Next, a method for manufacturing the stator 22 will be described. 4A and 4B are diagrams for explaining a method of winding the stator coil 28 around the stator core 27 of the vehicle electric rotating machine MG shown in FIG. 46 is a perspective view showing the overall structure of 46, and (c) is a state in which the segment coils 46 are inserted into the slots 42 of the stator core 27, and is viewed from the inner peripheral side to the outer peripheral side of the stator core 27 expanded in the circumferential direction. FIG. 4(d) is a diagram showing a state in which the segment coils 46 are connected by welding, which is developed in the circumferential direction of the stator core 27 and viewed from the inner peripheral side to the outer peripheral side.

As shown in FIG. 4A, the stator core 27 is formed by laminating a plurality of electromagnetic steel sheets 23 in the direction of the axis CL. Slots 42 are formed in the inner peripheral portion of the stator core 27 at equal angular intervals in the circumferential direction. Teeth 44 are formed between the slots 42 on the inner circumference of the stator core 27 . Note that the shape of the slots 42, the number of slots 42, and the like shown in FIG. 4(a) do not necessarily match the actual ones.

As shown in FIG. 4B, the segment coil 46 is composed of a so-called rectangular conductor having a rectangular longitudinal plate-like cross section and an insulating coating such as enamel formed on the surface thereof. The segment coil 46 is bent into a substantially U shape. The segment coil 46 includes a first arm portion 46a and a second arm portion 46b linearly extending in the same direction on the left and right sides of the U shape, and a base portion of the first arm portion 46a and a base portion of the second arm portion 46b. and a connecting portion 46c connecting the . The insulating coating is removed from both the tip portion of the first arm portion 46a and the tip portion of the second arm portion 46b.

As shown in FIG. 4(c), each arm 46a, 46b of the segment coil 46 is inserted into the slot 42 with the insulating paper 52 pre-inserted into the slot 42. As shown in FIG. As a result, the distal ends of the arm portions 46 a and 46 b of the segment coil 46 protrude from one end of the stator core 27 . Also, the insulating paper 52 is inserted between the slot 42 and the arm portions 46a and 46b of the segment coil 46 inserted therein.

As shown in FIG. 4( d ), portions of the arm portions 46 a and 46 b of the segment coil 46 protruding from the stator core 27 are bent in the circumferential direction of the stator core 27 . Also, the tip of the first arm portion 46a of the segment coil 46 and the tip of the second arm portion 46b of the other segment coil 46 are welded to form the welded portion 66. As shown in FIG. By electrically connecting the plurality of segment coils 46 to each other by the welding portions 66 in this way, the stator coil 28 wound around the teeth 44 is formed. Welding is, for example, TIG (Tungsten Inert Gas) welding.

As described above, in the manufacturing process of the stator 22, the arms 46a and 46b of the segment coils 46 are inserted into the slots 42. At this time, if the coefficient of friction between the segment coils 46 and the insulating paper 52 is high, , the insulating paper 52 may be dragged by the segment coil 46 and moved, and the insulating paper 52 may be displaced from the slot 42 . In particular, when the insulating paper 52 is pre-applied with an adhesive, the insulating paper 52 tends to be dragged by the segment coil 46 during the insertion process of the segment coil 46 , and the insulating paper 52 tends to slip out of the slot 42 . When the insulating paper 52 is displaced from the slots 42 , the heat generated from the stator coil 28 is easily transferred to the rotor core 24 . As a result, the temperature of the rotor core 24 and the magnets 36 incorporated in the rotor core 24 may increase.

On the other hand, in the process of inserting the arm portions 46a and 46b of the segment coils 46 into the slots 42 in the manufacturing process of the stator 22, the segment coils 46 are inserted into the slots 42 in the direction of the axis CL of the stator core 27. The jig 68 is arranged in advance at a position on the opposite side and overlaps with the protrusion 58 of the insulating paper 52 when viewed in the inserting direction of the segment coil 46 , and the segment coil 46 is inserted into the slot 42 in this state. By arranging the jig 68 at the position described above, when the insulating paper 52 is dragged by the segment coil 46 in the process of inserting the arm portions 46a and 46b of the segment coil 46 into the slots 42 of the stator core 27, The protrusion 58 formed on the insulating paper 52 abuts against the jig 68, thereby restricting the movement of the insulating paper 52 and preventing the insulating paper 52 from shifting.

FIG. 5 shows that in the process of inserting the arm portions 46a and 46b of the segment coils 46 into the slots 42 of the stator core 27 in the manufacturing process of the stator 22, the segment coils 46 are inserted into the slots 42 in the direction of the axis CL of the stator core 27. It is the figure seen from the side (rear side of the paper surface) and the opposite side (the front side of the paper surface). Although FIG. 5 shows one of the slots 42 formed in the stator core 27, jigs 68 are arranged at the same positions as in FIG. 5 for the other slots 42 formed in the stator core 27 as well.

The jig 68 is positioned on the opposite side of the slot 42 of the stator core 27 to which the arm portions 46 a and 46 b of the segment coil 46 are inserted in the direction of the axis CL of the stator core 27 , that is, the segment coil 46 is inserted into the slot 42 . , the distal end portions of the arm portions 46a and 46b of the segment coil 46 are arranged on the side protruding from the stator core 27. As shown in FIG.

The jig 68 has a longitudinal shape and is arranged such that its longitudinal direction extends along the radial direction of the stator core 27 . Specifically, the jig 68 extends from the inner peripheral side of the stator core 27 through the openings 54 formed in the slots 42 to a position near the segment coil 46 in the radial direction of the stator core 27 . The tip of the jig 68 is restricted to a position inside the segment coil 46 in the radial direction of the stator core 27 .

Also, the jig 68 is arranged at a position where the tip thereof overlaps the protrusion 58 of the insulating paper 52 when viewed in the insertion direction of the segment coil 46 . As shown in FIG. 5 , when the stator core 27 is viewed in the insertion direction of the segment coil 46 , the radially outer end of the stator core 27 of the jig 68 overlaps the connecting portion 62 of the insulating paper 52 . The jig 68 is arranged at a position adjacent to the insulating paper 52 in the direction of the axis CL of the stator core 27 .

By arranging the jig 68 at the position described above, when the insulating paper 52 is dragged by the segment coil 46 in the process of inserting the segment coil 46 into the slot 42 of the stator core 27 in the manufacturing process of the stator 22, the insulating paper The movement of the insulating paper 52 is restricted by bringing the insulating paper 52 into contact with the jig 68 , thereby preventing the insulating paper 52 from slipping out of the slot 42 . In addition, one end 56a and the other end 56b of the insulating paper 52 are arranged at a position different from the position facing the opening 54 of the slot 42, specifically, at the position of the third portion 52c radially outward of the stator core 27. Therefore, the protrusion 58 is formed without being cut off, and the rigidity of the protrusion 58 is ensured. As a result, when the insulating paper 52 contacts the jig 68 during the process of inserting the segment coil 46 into the slot 42 (transitional period), deformation (for example, buckling) of the protrusion 58 is suppressed.

FIG. 6 is a flowchart for explaining the manufacturing process (manufacturing method) of the stator 22. As shown in FIG. The stator 22 is manufactured in the order of the first step S1 to the sixth step S6 shown in FIG.

In the first step S1 in FIG. 6, a stator core 27 is formed by laminating a plurality of electromagnetic steel sheets 23. As shown in FIG. In the second step S<b>2 , insulating paper 52 pre-bent into a shape that can be inserted into the slots 42 is inserted into each slot 42 of the stator core 27 . In addition, in the step of bending the insulating paper 52 into a shape that matches the shape of the slot 42, the protrusion 58 is also formed. In the third step S3, prior to inserting the segment coil 46, the jig 68 is arranged at a predetermined position. The predetermined position is the side opposite to the side where the segment coil 46 is inserted into the slot 42 of the stator core 27 described above, and the jig 68 when viewed in the direction in which the segment coil 46 is inserted. overlaps the protrusion 58 .

In a fourth step S<b>4 , segment coils 46 are inserted into slots 42 of stator core 27 . At this time, even if the insulating paper 52 is dragged by the segment coil 46 , the insulating paper 52 abuts against the jig 68 to prevent movement of the insulating paper 52 . Therefore, the insulating paper 52 is prevented from slipping out of the slot 42 . In the fifth step S5, when the segment coil 46 is inserted into each slot 42, one end of each arm 46a, 46b of the segment coil 46 is bent in the circumferential direction of the stator core 27. FIG. In a sixth step S6, the distal ends of the arms 46a and 46b of the segment coils 46 bent in the fifth step S5 are connected by welding.

As described above, according to this embodiment, the step of inserting the insulating paper 52 into the slots 42 of the stator core 27 (the second step S2) is performed, and the segment coils 46 are inserted into the slots 42 of the stator core 27. A step of arranging the jig 68 on the opposite side and at a position overlapping the projecting portion 58 when viewed in the direction in which the segment coil 46 is inserted (third step S3), and inserting the segment coil 46 into the slot 42 (second 4 step S4), even if the insulating paper 52 is dragged by the segment coil 46 in the process of inserting the segment coil 46 into the slot 42, the insulating paper 52 is brought into contact with the jig 68. The movement of the insulating paper 52 is suppressed, and the insulating paper 52 is prevented from slipping out of the slot 42 . Here, since it is not necessary to provide a locking groove forming portion in the slot 42 for preventing the displacement of the insulating paper 52, the number of segment coils 46 accommodated in the slot 42 is also suppressed from being reduced.

Further, according to this embodiment, the one end 56a and the other end 56b of the insulating paper 52 surrounding the segment coil 46 are arranged at the third portion 52c, which is a position different from the radially inner side of the segment coil 46. The rigidity of the protrusions 58 formed on the insulating paper 52 is ensured. Therefore, when the protrusion 58 contacts the jig 68 in the process of inserting the segment coil 46 into the slot 42, deformation of the protrusion 58 by the jig 68 can be suppressed. In addition, since the space 64 is formed between the protrusion 58 and the segment coil 46, the oil flows into the space 64 formed between the protrusion 58 and the segment coil 46, thereby causing the stator core 27 and the stator coil 28 to move. (Segment coil 46) is improved in cooling performance. In relation to this, radiant heat from the stator coil 28 to the rotor 20 is also reduced, so the temperature of the magnets 36 incorporated in the rotor core 24 is also reduced. As a result, the heat resistance of the magnets 36 and the segment coils 46 can be alleviated, so that the magnets 36 and the segment coils 46 can be manufactured from less expensive materials than conventional ones.

Another embodiment of the present invention will now be described. In the following description, the same reference numerals are given to the parts common to the above-described embodiment, and the description thereof is omitted.

FIG. 7 is an enlarged sectional view showing the periphery of slots 42 formed in stator core 27, corresponding to another embodiment of the present invention. FIG. 7 corresponds to FIG. 3 of the first embodiment described above. Since the shapes of the stator core 27 and the slots 42 are the same as in the above-described embodiment, they are given the same reference numerals and their description is omitted.

As shown in FIG. 7, an insulating paper 80 is interposed between the walls (48a, 48b, 50) forming the slots 42 of the stator core 27 and the plurality of segment coils 46 accommodated in the slots 42. ing. The insulating paper 80 is appropriately folded so as to surround the plurality of segment coils 46 accommodated in the slots 42 when viewed in the insertion direction of the segment coils 46 .

The insulating paper 80 has a first portion 80a interposed between the side wall 48a of the slot 42 and the segment coil 46, and a second portion 80b interposed between the side wall 48b of the slot 42 and the segment coil 46. , a third portion 80c interposed between the bottom wall 50 of the slot 42 and the segment coil 46, and a fourth portion 80d located radially inside the stator core 27. As shown in FIG.

A fourth portion 80 d of the insulating paper 80 located radially inside the stator core 27 , i.e., on the side of the opening 54 of the slot 42 , is formed with a protrusion 82 protruding toward the inner peripheral side of the stator core 27 . The projecting portion 82 is formed in a convex shape projecting toward the inner peripheral side of the stator core 27 .

When viewed in the insertion direction of the segment coil 46, the projection 82 has a triangular cross section. Specifically, the projecting portion 82 is composed of a pair of inclined portions 84a and 84b having a predetermined inclination with respect to the long side of the segment coil 46. As shown in FIG. The tip of the inclined portion 84a and the tip of the inclined portion 84b are continuously connected, so that the cross section of the projecting portion 82 is formed in a triangular shape. Moreover, a space 86 surrounded by the protrusion 82 and the long sides of the segment coil 46 is formed by the protrusion 82 protruding toward the inner peripheral side of the stator core 27 .

Even if the protrusions 82 are configured as described above, when inserting the segment coils 46 into the slots 42 of the stator core 27, a jig 68 (see FIG. 5) is placed at the same position as in the first embodiment. By arranging them in advance, even if the insulating paper 80 is dragged by the segment coil 46 , the protrusions 82 abut against the jig 68 to prevent the insulating paper 80 from slipping out of the slots 42 . In addition, the oil flowing through the space 86 effectively cools the stator core 27 and the stator coil 28 by the oil flowing through the space 86 . Therefore, this embodiment can also obtain the same effect as the above-described embodiment.

FIG. 8 is an enlarged sectional view showing the periphery of slots 42 formed in stator core 27, corresponding to still another embodiment of the present invention. FIG. 8 corresponds to FIG. 3 of the first embodiment described above. Since the shapes of the stator core 27 and the slots 42 are the same as in the above-described embodiment, they are given the same reference numerals and their description is omitted.

As shown in FIG. 8, insulating paper 90 is interposed between the wall surfaces forming the slots 42 of the stator core 27 and the plurality of segment coils 46 accommodated in the slots 42 . The insulating paper 90 is appropriately folded so as to surround the plurality of segment coils 46 accommodated in the slots 42 when viewed in the insertion direction of the segment coils 46 .

The insulating paper 90 has a first portion 90a interposed between the side wall 48a of the slot 42 and the segment coil 46, and a second portion 90b interposed between the side wall 48b of the slot 42 and the segment coil 46. , a third portion 90 c interposed between the bottom wall 50 of the slot 42 and the segment coil 46 , and a fourth portion 90 d located radially inside the stator core 27 .

A fourth portion 90 d of the insulating paper 90 located radially inside the stator core 27 , i.e., on the side of the opening 54 of the slot 42 , is formed with a projection 94 protruding toward the inner circumference of the stator core 27 . The projecting portion 94 is formed in a convex shape projecting toward the inner peripheral side of the stator core 27 .

The insulating paper 90 is formed in a U-shape protruding toward the inner peripheral side of the stator core 27 from the segment coil 46 when the projecting portion 94 is viewed in the inserting direction of the segment coil 46 . Specifically, the projecting portion 94 includes a pair of extending portions 96a and 96b extending from the ends of the first portion 90a and the second portion 90b to the inner peripheral side of the segment coil 46, and a pair of the extending portions 96a and 96b. and a connection portion 98 that connects the ends of the extension portions 96a and 96b. A pair of extending portions 96a and 96b extend further to the inner peripheral side of the stator core 27 than the segment coil 46, thereby forming a space 99 surrounded by the projecting portion 94 and the long sides of the segment coil 46. be.

Even if the projecting portion 94 is configured as described above, when inserting the segment coil 46 into the slot 42 of the stator core 27, the jig 68 (see FIG. 5) is placed at the same position as in the first embodiment. By arranging them in advance, even if the insulating paper 90 is dragged by the segment coil 46 , the protrusions 94 contact the jig 68 to prevent the insulating paper 90 from slipping out of the slots 42 . In addition, the oil flowing through the space 99 effectively cools the stator core 27 and the stator coil 28 by the oil flowing through the space 99 . Therefore, in this embodiment as well, the same effect as in the above-described embodiment can be obtained.

FIG. 9 is an enlarged sectional view showing the periphery of slots 42 formed in stator core 27, corresponding to still another embodiment of the present invention. FIG. 9 corresponds to FIG. 3 of the first embodiment described above. Since the shapes of the stator core 27 and the slots 42 are the same as in the above-described embodiment, they are given the same reference numerals and their description is omitted.

As shown in FIG. 9, insulating paper 100 is interposed between the wall surface forming slot 42 of stator core 27 and the plurality of segment coils 46 accommodated in slot 42 . The insulating paper 100 is appropriately folded so as to surround the plurality of segment coils 46 accommodated in the slots 42 when viewed in the insertion direction of the segment coils 46 .

The insulating paper 100 has a first portion 100a interposed between the side wall 48a of the slot 42 and the segment coil 46, and a second portion 100b interposed between the side wall 48b of the slot 42 and the segment coil 46. , a third portion 100c interposed between the bottom wall 50 of the slot 42 and the segment coil 46, and a fourth portion 100d located radially inside the stator core 27. As shown in FIG.

A fourth portion 100 d of the insulating paper 100 located radially inside the stator core 27 , i.e., on the side of the opening 54 of the slot 42 , is formed with a protrusion 104 protruding toward the inner peripheral side of the stator core 27 . Projection portion 104 is formed in a convex shape protruding toward the inner peripheral side of stator core 27 .

When viewed in the insertion direction of the segment coil 46, the projection 104 has a trapezoidal cross section. Specifically, the projecting portion 104 is a pair of inclined portions 106a and 106b inclined at a predetermined gradient from the end portions of the first portion 100a and the second portion 100b, and a connection connecting the tips of the pair of inclined portions 106a and 106b. 108 and . Moreover, a space 109 surrounded by the protrusion 104 and the long sides of the segment coil 46 is formed by the protrusion 104 protruding toward the inner peripheral side of the stator core 27 .

Even if the projecting portion 104 is configured as described above, when inserting the segment coil 46 into the slot 42 of the stator core 27, the jig 68 (see FIG. 5) is placed at the same position as in the first embodiment. By arranging in advance, even if the insulating paper 100 is dragged by the segment coil 46 , the projecting portion 104 contacts the jig 68 to prevent the insulating paper 100 from slipping out of the slot 42 . In addition, the oil flowing through the space 109 effectively cools the stator core 27 and the stator coil 28 by the oil flowing through the space 109 . Therefore, this embodiment can also obtain the same effect as the above-described embodiment.

FIG. 10 is an enlarged cross-sectional view showing the periphery of slots 42 formed in stator core 27, corresponding to still another embodiment of the present invention. FIG. 10 corresponds to FIG. 3 of the first embodiment described above. Since the shapes of the stator core 27 and the slots 42 are the same as those of the first embodiment described above, the same reference numerals are given and the description thereof is omitted.

As shown in FIG. 10, an insulating paper 110 is interposed between the wall forming the slot 42 of the stator core 27 and the plurality of segment coils 46 accommodated in the slot 42 . The insulating paper 110 is appropriately folded so as to surround the segment coil 46 accommodated in the slot 42 when viewed in the insertion direction of the segment coil 46 .

The insulating paper 110 has a first portion 110a interposed between the side wall 48a of the slot 42 and the segment coil 46, and a second portion 110b interposed between the side wall 48b of the slot 42 and the segment coil 46. , a third portion 110 c interposed between the bottom wall 50 of the slot 42 and the segment coil 46 , and a fourth portion 110 d located radially inside the stator core 27 .

A fourth portion 110d of the insulating paper 110 located radially inward of the stator core 27, i.e., on the side of the opening 54 of the slot 42, is formed with a projection 114 protruding radially inward of the stator core 27. . Protrusion 114 is formed in a convex shape protruding toward the inner peripheral side of stator core 27 .

When viewed in the inserting direction of the segment coil 46, the projection 114 has a triangular cross section. The projecting portion 114 is composed of a pair of inclined portions 116a and 116b inclined at a predetermined gradient. The projecting portion 114 is formed by bending a portion of the fourth portion 110d forming the insulating paper 110 into a triangular cross-sectional shape. In this way, the protrusion 114 may be formed on a part of the fourth portion 110d. Moreover, a space 118 surrounded by the protrusion 114 and the long sides of the segment coil 46 is formed by the protrusion 114 protruding toward the inner peripheral side of the stator core 27 .

Even if the projecting portion 114 is configured as described above, when inserting the segment coil 46 into the slot 42 of the stator core 27, the jig 68 (see FIG. 5) is placed at the same position as in the first embodiment. By arranging in advance, even if the insulating paper 110 is dragged by the segment coil 46 , the protrusion 114 contacts the jig 68 to prevent the insulating paper 110 from slipping out of the slot 42 . In addition, the oil flowing through the space 118 effectively cools the stator core 27 and the stator coil 28 by the oil flowing through the space 118 . Therefore, this embodiment can also obtain the same effect as the above-described embodiment.

FIG. 11 shows the stator core 27 on the side where the segment coils 46 are inserted in the process of inserting the arms 46a and 46b of the segment coils 46 into the slots 42 of the stator core 27, which corresponds to still another embodiment of the present invention. It is the figure seen from the other side. FIG. 11 corresponds to FIG. 5 of the first embodiment described above. Since the shapes of the stator core 27 and the slots 42 are the same as those of the first embodiment described above, the same reference numerals are given and the description thereof is omitted.

As shown in FIG. 11, insulating paper 120 is interposed between the wall forming slot 42 of stator core 27 and the plurality of segment coils 46 accommodated in slot 42 . The insulating paper 120 is appropriately folded so as to surround the segment coil 46 accommodated in the slot 42 when viewed in the insertion direction of the segment coil 46 .

The insulating paper 120 has a first portion 120a interposed between the side wall 48a of the slot 42 and the segment coil 46, and a second portion 120b interposed between the side wall 48b of the slot 42 and the segment coil 46. , a third portion 120 c interposed between the bottom wall 50 of the slot 42 and the segment coil 46 , and a fourth portion 120 d located radially inside the stator core 27 .

A portion of the first portion 120a protruding from the stator core 27 in the direction of the axis CL is bent in a tapered shape (see FIG. 12). Similarly, the second portion 120b has a tapered portion that protrudes from the stator core 27 in the direction of the axis CL (see FIG. 12). The tapered bent portion of the first portion 120a and the tapered bent portion of the second portion 120b are bent away from each other. Therefore, when the first portion 120 a and the second portion 120 b are viewed in the direction of the axis CL of the stator core 27 , neither the first portion 120 a nor the second portion 120 b overlap the segment coil 46 .

Also in the present embodiment, similarly to the first embodiment described above, the fourth portion 120d of the insulating paper 120 positioned on the radially inner side of the opening 54 (inner side in the radial direction) of the stator core 27 has an inner peripheral side of the stator core 27. A projecting portion 58 projecting toward is formed. Furthermore, a jig 68 is provided on the opposite side of the slot 42 of the stator core 27 to which the segment coil 46 is inserted, and at a position overlapping the protrusion 58 when viewing the stator core 27 in the direction in which the segment coil 46 is inserted. are placed. Therefore, even if the insulating paper 120 is dragged by the segment coil 46 in the process of inserting the segment coil 46 into the slot 42 of the stator core 27, the insulating paper 120 is pulled by the protrusion 58 coming into contact with the jig 68. Since it is prevented from being displaced from the slot 42, the same effect as in the first embodiment described above can be obtained.

Furthermore, in this embodiment, in addition to the above configuration, the segment coils 46 are inserted into the slots 42 of the stator core 27, and the side opposite to the side where the segment coils 46 are inserted. A first tapered contact jig 122a (hereinafter referred to as first jig 122a) is arranged at a position overlapping the tapered portion of the first portion 120a of the insulating paper 120 . Further, the tapered shape of the second portion 120b of the insulating paper 120 is viewed from the side opposite to the side where the segment coil 46 is inserted into the slot 42 of the stator core 27 and in the direction in which the segment coil 46 is inserted. A second tapered abutting jig 122b (hereinafter referred to as a second jig 122b) is arranged at a position overlapping the portion formed in the .

As shown in FIG. 11, the first jig 122a comes into contact with the tapered portion of the first portion 120a when the insulating paper 120 moves in the inserting direction of the segment coil 46 (the front side of the paper surface in FIG. 11). placed in position. That is, when the stator core 27 is viewed from the side opposite to the side where the segment coils 46 are inserted, the first jig 122a is arranged at a position overlapping the tapered portion of the first portion 120a. Similarly, the second jig 122b is arranged at a position where it contacts the tapered portion of the second portion 120b when the insulating paper 120 moves in the insertion direction of the segment coil 46. As shown in FIG. That is, when the stator core 27 is viewed from the side opposite to the side where the segment coils 46 are inserted, the second jig 122b is arranged at a position overlapping the tapered portion of the second portion 120b.

FIG. 12 is a diagram schematically showing a state in which FIG. 11 is viewed from the inner side to the outer side in the radial direction of the stator core 27. As shown in FIG.

As can be seen from FIG. 12 , in the process of inserting the segment coils 46 into the slots 42 of the stator core 27 , the side opposite to the side where the segment coils 46 are inserted into the slots 42 in the direction of the axis CL of the stator core 27 (lower side of the drawing). , a jig 68, a first jig 122a, and a second jig 122b are arranged. Moreover, the jig 68 is arranged at a position where it abuts on the protrusion 58 when the insulating paper 120 moves in the inserting direction of the segment coil 46 (downward in the plane of the drawing). The first jig 122a is arranged at a position where it comes into contact with the tapered portion of the first portion 120a when the insulating paper 120 moves in the inserting direction of the segment coil 46. As shown in FIG. The second jig 122b is arranged at a position where it contacts the tapered portion of the second portion 120b when the insulating paper 120 moves in the insertion direction of the segment coil 46. As shown in FIG.

Therefore, if the insulating paper 120 is dragged by the segment coil 46 in the process of inserting the segment coil 46 into the slot 42 of the stator core 27, the insulating paper 120 will be removed from the jig 68, the first jig 122a, and the first jig 122a. The insulating paper 120 is preferably prevented from slipping out of the slot 42 by abutting on the two jigs 122b.

As described above, the tapered portion is added to the insulating paper 120 of the present embodiment, and the tapered portion of the insulating paper 120 is formed in the process of inserting the segment coil 46 into the slot 42 . By arranging the first jig 122 a and the second jig 122 b that can abut on the parts, the insulating paper 120 is added to the jig 68 in the process of inserting the segment coil 46 into the slot 42 of the stator core 27 . By abutting against the first jig 122a and the second jig 122b, the slippage of the insulating paper 120 from the slot 42 is further prevented.

Since the insulating paper 120 has a tapered portion that protrudes from the stator core 27 , the portion (coil end) of the stator coil 28 that protrudes from the stator core 27 also has an axial line corresponding to the portion that the insulating paper 120 protrudes from the stator core 27 . CL becomes longer. On the other hand, in each of Examples 1 to 5 described above, since the tapered portion is not formed in the insulating paper, the insulating paper hardly protrudes from the stator core 27 . In relation to this, the length of the portion (coil end) of the stator coil 28 protruding from the stator core 27 can be shortened.

Although the embodiments of the present invention have been described in detail above with reference to the drawings, the present invention is also applicable to other aspects.

For example, in each of Examples 1 to 5 described above, the first jig 122a and the second jig 122b described in Example 6 may be added as appropriate.

Also, the projections (58, 82, 94, 104, 114) in each of the above-described embodiments are one aspect, and are not necessarily formed in these shapes. In other words, the projecting portion may be appropriately applied as long as it has a shape that can contact the jig 68 in the process of inserting the segment coil 46 into the slot 42 (transitional period of insertion) by protruding to the inner peripheral side of the stator core 27 . can be done.

Further, in each of the above-described embodiments, one end 56a and the other end 56b of each insulating paper (52, 80, 90, 100, 110, 120) are inserted between the bottom wall 50 and the segment coil 46. Although they are arranged at positions (52c, 80c, 90c, 100c, 110c, 120c), the present invention is not necessarily limited to this. Specifically, one end of the insulating paper is placed at the position of the first portion interposed between the side wall 48a and the segment coil 46 or the position of the second portion interposed between the side wall 48b and the segment coil 46. and the other end may be arranged. In this way, if one end and the other end of the insulating paper are arranged at a portion different from the fourth portion of the insulating paper located radially inward of the stator core 27, the rigidity of the projection formed on the insulating paper is preferably ensured.

Also, in the above-described embodiment, six segment coils 46 are accommodated in each slot 42, but the number of segment coils 46 is not necessarily limited to six, and can be changed as appropriate.

It should be noted that what has been described above is just one embodiment, and the present invention can be implemented in aspects with various modifications and improvements based on the knowledge of those skilled in the art.

22: Stator 27: Stator core 42: Slot 46: Segment coil (conductor)
52, 80, 90, 100, 110, 120: insulating paper 54: opening 56a: one end 56b: other end 58, 82, 94, 104, 114: projections 64, 86, 99, 109, 118: space 68: healing Tool MG: Rotating electric machine for vehicle

Claims (3)

An annular stator core, a slot which is a groove hole formed in the inner peripheral portion of the stator core and penetrates the stator core, and is inserted between the wall surface of the slot and the conductor wire accommodated in the slot, and surrounds the conductor wire. and an insulating paper disposed so as to surround the stator core, wherein a projecting portion projecting toward the inner peripheral side of the stator core is formed on the inner side of the insulating paper in the radial direction of the stator core. a stator manufacturing method of
inserting the insulating paper into the slot of the stator core;
disposing a jig at a position opposite to the side of the stator core where the conductor wire is inserted into the slot and overlapping the protrusion when viewed in the direction in which the conductor wire is inserted into the slot of the stator core; A method of manufacturing a stator for a rotating electric machine for a vehicle, comprising: inserting the lead wire into the slot. 2. The method of manufacturing a stator for a rotating electric machine for a vehicle according to claim 1, wherein one end and the other end of said insulating paper surrounding said conductive wire are arranged at positions different from radially inner positions of said stator core. 3. The method of manufacturing a stator for a rotating electrical machine for a vehicle according to claim 1, wherein a space surrounded by said projection and said conductor is formed between said projection and said conductor.

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